Method of making hinges



METHOD OF MAKING HINGES Filed Jgly 24. 1929 4 sheets-sheet 1 lll lll Z1 l /50 i y P1@ 4. 34 H 34 CAQOLUSLEKSLRMAN i8 s F ll\\ Z1 I www 4Z 52 6 ATTQRNEY.

April 26, 1932. c. L EKSERGIANv 1,855,710

. Filed July 24, 1929 4 Sheets-Sheet 2 IN VENTO RoLusLlks N. 7.0M

A TTORNE Y.

April 26, 1932 c. l.. EKSERGIAN 1,855,710

METHOD OF MAKING HINGES Filed July 24, 1929 sheets-sheet 4 y PKI. 418

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1N VEA/TOR. I

CAROLUS LEIERGLAN ATTORNEY.

Patented Apr. 26, 1932 UNITED STATES PATENT OFFICE CAROL'US L. EKSEBGIAN, 0F PHILADELPHIA, PENNSYLVANIA, ABSIGNOB T0 EDWARD G. BUDD-MANUFACTUBING C0., OF PHILADELPHIA, PENNSYLVANIA, A CORPORAL- TION F PENN BYLVAN I.A

METHOD OP MAKING HINGES Application led July 24,

y s door hinges. These hinges require knuckles of very superior finish and are very generally provided with hoods for the purpose of improving the finish, excluding dust and increasing the strength. These hoods have made hinges of this class relatively d-iflicult to form as compared with hinges of the knuckle type. They have commonly been formed as separate pieces, or by drop forging in one piece with the stamping. The outstanding object of my invention is the continuous rolling of hinges of this type from bar stock. It is well known that continuous rolling of things of this type from hot bar stock is one of the most economical methods of fabricating articles, especially small articles. But rolling has had its limitations in the formation of hinge butts. It is an object of my invention to remove these limitations to so great an extent as to enable hooded hinge butts of superior strength of finish to be produced by this highly economical process.

According to my method I utilize hot bar stock, preferably of rectangular cross section. Blanks of such lengths as to give them mass suiiicient to embody the hinge butt are successively severed from this bar. The outer end of a severed blank is engaged first by the rolls, the rolls definitely biting into the vouter end. This end is rolled in advance of the hooded end. It is rolled by cylindrical rolling, under a differential rolling action. Then the main body and the inner end of the blank are rolled to form the remainder of the blank and the knuckle which embodies the rolled portion. This latter is formed byradial rolling of the gea-r tooth variety. The arrangement is such that the top of the hood is rolled approximately on the pitch circle ofthe gear tooth action. The action is an action of combined rolling and extrusion. The mass of metal at the inner end of the blank is pocketed, gear tooth rolled radially, and simultaneously extruded to form the ears of the butt and of the hood.

1929. Serial No. 380,520.

The vwhile through the cylindrical rolling of the shank portion per se there is developed a hold down action which resists displacement of the mass under the gear tooth rolling in the formation of the knuckle. In the knuckle formation the gear tootb rolling first forms a pocketed depression and sizes the exterior o the hood and finally sizes the depression to form-the interior and size the ears. Infurtherance of exactitude the formation of the knuckle is arranged to take place under an equalized rolling action as distinguished from the diil'erential rolling action under which the shank is formed.

Figures 1 to 7 show diagrams illustrating the rolls employed and the various steps of the method.

Figures 8 and 9 are respectively perspective views of the hinge butt as rolled by my method and the hinge butt as ready for use in the automobile.

Figures 11- and 12 are respectively perspective views of the co-acting dies.

Figures 13 and 14 are respectively sectional side elevation and plan of the machine for carrying out the method.

Figures 15 and 16 are res ectively sectional side elevation and plan o the upper die of Fi 11 and igures 17 and 18 are respectively plan and sectional side elevation of the lower die of Fig. 12, the side elevations being shown in the relative positions which they occupy in the machine.

Figure 19 is a detail of cross section in line 19/19 of Fig. 14.

As clearly appears in the perspective of Fig. 9, the completed hinge butt comprises a shank 16 and a hooded knuckle 17. This knuckle is formed integrally with the shank 16. It comprises hood 18 in the form of an approximately semi-circular reverse bent extension of the shank 16 of the same or different wall thickness together with integrally formed ears 19 closing the ends of the hood 18, constituting a bracing inter-connection between the hood 18 and the shank 19, and

f also the bearing members of the knuckle, conwall of the hood of the knuckle. truly complemental to the inner surface 39 of as rolledyb my method the hinge is initially given the orm shown in Fi 8 in which the shank has a right an le ben Referring first to igures 1 to 7 and particularly at the moment to Fig. 1, there are used upper and lower rolls -21 appro-l priately geared together as used in the machine. These rolls are provided with cylindrical portions 22 22 having a rolling contact with the blank, and with adjoining gear tooth portions 23, 23 having a relation to each other of gear teeth, that is to say, a radial relative movement and a combined radial sliding and rolling action essentially similar to the teeth of gears. The cylindrical por tions 22, 22 merge into the ear tooth portions 23, 23 by arcs 24, 24. he cylindrical portions 22, 22 are of different relative diameter. The rolls 20-21 are geared together on a 1-1 basis as will be seen and there is therefore a differential rolling action as between the cylindrical portions 22, 22', that one of greater diameter in connection with roll '.21

moving at a greater rate than that of lesser.

diameter in connection with roll 20. The arcs 24, 24 differ in radius and they emanate `from the terminii of the cylindrical portions' 22, 22. The angular relation of the rolls is" But both these complemental portions 22, 22

are provided with rectangular de ress ions 30, of half the cross section of t e shank of the hin butt to be formed. Beyond the arcs 24, 24 this de ression of the roll 21 reoedes at 31, radiali; inwardly at full cross section of the shank and into the radial pocket 32 of the tooth portions 23, 23 of the rolls. The epression 30 of the roll 20 fades out in arc 24. 'Pocket 32 is of the form of the exterior of the hooded knuckle of the hinge butt. Its bottom 33 is precisel of the form of the exterior of the knuckle. he bottom 33 is merged smoothly into the bottom of the recess 30 at the arc 24. But this merging is on a line 34 which passes to the left of the center 35 of the lower roll. In other words, it converges outwardly toward the radius 36 to the terminus 26 of the cylindrical portion 22 of the roll.

Gear tooth 37 of roll 20 enters this pocket as shown in dotted lines. It does not bottom in the pocket, but is spaced from the bottom a depth equal to the desired thickness of the Nor is it the hood of the knuckle (see Figs. 6 and 7 as well as Fig. l), It is complemental to the inner surface 39 only on its ofv side 40 and at the flank 41 on its near side. Between its end 42 and the point'41 it is cut away as at 43. It is non-complemental in the part cut away. There is a smooth merging of the rounded flank 41 into lthe arc 24 of the roll 20. Yet further, the tooth 37 does not contact with the ends ofthe pocket 32. It falls short at each end of contact by a space equal in thickness to thehthickness of the ears of the hooded knuckle.

Approximately, when` fully entered in pocket 32, 23 occupies a position in space between the ears 19 of Figs. 8 and 9. An approximate pitch circle 44 of the tooth 37 passingthrough the flank 41 is tangen and of equal diameter to a circle 45 compre ending the. top and mouth of theA ocket 32. Thus, the gear tooth enga ement o the roll is oie of substantially equa ized ripheral action as distinguished from the iierential action of the cylindricalportions 22, 22 of different diameter.

With this understanding of the general geometrical relations of the parts of the rolls `employed, the various steps of the method lar cross section is shown with its outer end 47 entered between the rolls 20 and 21. The rolls being progressed in the direction shown by the arrows, the outer end 47 is rolled down into the shank portion of the die 30 as shown in Figure 3. The action is a lcylindrical rolling action between the cylindricalportions 22, 22 of the rolls 20, 21. It is di erential by reason of the fact that the portion 22 of roll 20 is of lesser diameter than the portion 22 of the roll 21. It is rolled down to the exact dimension of the shank.

The mass of metal before the rolls quickly fills the spaces between the terminal ends. v

25-26 of the cylindrical portionsv and the arc sha ed portions 24, 24. The mass of metal in t is space in the stage of the rocess illustrated in Fig. 3 has a considera le bulge 48 being much greater in transverse cross section at this point than at the point between the Hank 41 of tooth 37 and the closest 'point of' the roll 21, the diierential cylindrical rolling being effected between the surfaces 22, 22 together with this enlarged mass 48 anchors 'and aligns the blank, and exerts a holding reaction against the following forging action upon the inner end of the blank 46. This action just starting in the stage of Fig. 3 is shown well progressed in Fig. 4.

In Fig. 4 the differential cylindrical rolling of the outer end of the shank is completed. The terminii 25-26 of these portions of the rolls lie on the line of centers 29 of the roll. The arcs 24, 24 are concentric. The bend of the shank has been formed through the coinasumo cidence of these arcs. The bulged mass of metal 48 has been reduced to the dimensions of the bend and the excess metal extruded between the fiank 31 of the tooth 37 and the adjacent face of roll 21. The radial gear tooth rolling is well under way.

This radial ar tooth rolling instituted in Fig. 3 starts with the progress of the flank 41 over the end of the arc portion 24', and continues with the downward movement of thi f flank substantially arallel to the line r 4 through the stage of ig. 4 and into the stagrx of Fig. 5 in which stage the flank 41 lies approximately upon the itch circles 44-45 and closely adJacent to t e line of centers 29. Passing from the institution in Fig. 3 to the two phases in Figs. 4 and 5 flank 41 has progressed radially inwardly around and beyond the bend 49 substantially parallel to line 34 and forming accurately the inner-portion of the shank 19 between the bend and the knuckle. In this formation extrusion from the bul e 48 as the arcs 24, 24 have approache each other has taken its art, the metal bein forced out under the ro ling roach of t e arcs 24, 24 and regulated 1n its dimensions by the proximity of the fiank 41 to the face of roll 20. But in the stage of Fig. 4 Hank 41 has reached its closest proxilnlty to line 34 defining the face of the roll 21 and the rolling action of arcs 24, 24 has ceased. From this stage into the stage of Fig. 5 flank 41 moves radially inwardly substantially parallel to the line 34 shaping a further section of the shank 16 immediatel adjoining the knuckle 17, in fact, shaping 1t right up to the mouth of the pocket 32. In the progress from the stage of Fi 4 to that of Fig. 5 the arc portions 24, .24 have left each other. The formation of this root connection between the shank and the'knuckle therefore is wholly by the radial movement of the flank 41 assisted by slight extrusion incident to the gear rolling action of the point 42 ofthe tooth 37.

This gear rolling action of the point of tooth 37 is instituted in Fig. 4. In Fig. 4 the inner end 38 of the blank is under radial rolling action between the cut-away portion 43 of the side of the tooth and the opposite side wall of pocket 32. This rolling action fills the bottom of the pocket as shown in Fi 5 and rolling action is instituted on the polnt of tooth 37. There is very little if any extruding action incident to this rolling past' flank 41 for the reason that the general radial movement of tooth 37 into pocket 32 exerts a strong downward component, but such as there is may be sufficient to raise the bend of the outer end of shank 19 from the face of the roll as appears in Fig. 5. There is no alteration in dlmension of the shank because flank 41 is moving parallel to line 34. But there is at this stagedecided extrusion laterally from the inner end 46 of the blank hood 18 is ormed by into the space between the ends of tooth 37 and the ends of pocket 32. This is shown by the dotted line hei ht 50 to which the extrusion may have reac ed.

There is instituted in Fig. 5 what may be termed a rocking movement of the tooth 37 about the oint of flank 41 on the pitch circle 44, since ank 41 has reached the end of its radial sliding movement while the opposite flank 40 has just started int the mass of `metal 38. As the rolls progress in the direction of the arrows, this rocking movement sinks tooth 37 under the rolling action into the depth of the metal`38 rollin and extruding it to completely fill the poc et 32 and to completely form the ears 19 of the knuckle of the hin e. The endmost wall 51 of the a combined rolling and extruding action, t e int of the tooth 37 as it approaches the ttom of the pocket restrictlng the flow of the metal before the rolls to a cross section less than that of the bulged portion 52 lying behind the rolls' and between the cut away portion 41a andthe line 34. The rolling action on\this bulged portion 52 extrudes the metal between the point of the tooth and the outer side wall of pocket 32 and the inner flank 40 rolls it accurately to dimension as it is extruded. At full depth of the tooth the flank 40 being shaped complemental to the inner surface of the hood 18 accurately forms this surface.

Finally, in the stage of Fig. 7 the tooth 37 starts to leave the pocket 32. Flank 40 ,Y leaves the inner face of the hood 18 which it has formed. At this point the tooth in effect rocks about the outer end 51 of the hood. Flank 41 is no longer an a proximately stationary part. It is lifte by the rocking action and carried away from line 34. But the relation of the arts is such that the point of the tooth 3 sweeping outwardly approximately with the edge 51 as a center, describes a path of movement which reduces to final dimension the inner wall 39 of the hood 18, extruding the metal past the flank 40 and perhaps slightly past the flank 41 which at this stage has moved but slightly if at all, from its position of closest proximity to the face 34. Thereupon tooth 37 passes out of the pocket withoutfurther action except as the point of tooth 37 may smooth the inner surface of the inner wall 39 of the back of the hood 18.

There has been produced at the termination of the rolling the hinge butt of Fig. 8 having a bent shank and having also a Hash 53 and 54 at its opposite ends. The flash being removed and the shank straightened by any desired method, the hinge butt has the usuable form of Figure 16. The flash 53 of Fig. 7 is the result of the initial bite of Figure 2 on the outer end 47 of the blank. The fiash 54 is the result of the cut off action of the rear end of the blank by cut-0E portions 55-56 of the dies.

The mechanical details of the construction of the die is more fully shown in the perspectives of Figs. 11 and 12 and the projections of Figs. 15 to 18. In these figures the configuration corresponding to the diagrammatic showing of Figs. 1 to 7 are similarly numbered. The dies are made as inserts for the rolls arranged to be screwedor bolted on. One half of the configuration of the shank 16 is made in one die and the other half in the other. The initial bite of the outer end of the dies upon the billet is by the advance edge portions 57. The final bite is by the rear portions 5556. These are cylindrical about the axes of the rolls. Beyond them the dies are opened awa from each other b recesses 58. The cylindyrical portions 52 o the dies are carried beyond the bend 49 of the shank and flank also the pocket 32. Arc shaped surfaces 24, 24 roject without the c lindrical fp Y . nessesof two end walls 19. The end walls ex- Yoo tend by their portions (Fig. 8) a distance up the shank 16 and this extension is marked by a continuation of thecontour of the shoulder 50 into the arc shaped surfaces 24.

The machine of Figs. 13 and 14 operates the rolls and carries out the complete method.y

It comprises the rolls 20 land 21, roll shafts 61-62, and inter-roll gears 63.. 'Ihel main bodies of the rolls and gears are respectively of the same diameter. The rolls yare driven by a train of gears 64extending from the lower shaft 62 first tothe upper of two counter-v' shafts 65 and then to the lower, which lowerv is provided with a ily-wheel 66 for driving. In the rear of the rolls is provided a pair of rollers 67 for feeding in bar stock 68. Be.

tween the feed-in rolls 67 and the forming rolls 20 and 21 is erected blank cut-off land feeding-in mechanism 69. This mechanism 69 is shown as ybeing provided with'reciproeating cutting' dies 70 operated from an eccentric 7ll driven by gearing 72 from thel roll axis 62. The severed blanks are dropped on atrackway 73 between cut-off mechanism 69 and the rolls and having their inner .ends projectingv between the rolls. The tracks comprise va pair lof spaced rails 74 as clearly appearsin Fig. 19 and Fig. 14. The blank -`is held upon and between the flanges of these rails as appears in the detail of Fig. 19. A finger 7 zoscillatable about a pivotin shaft 76 projects into space betweenk rails 4 and behind the end of the blank as severed. The

finger is oscillated in time with the movement of the dies on the rolls by means of bell crank 76 operated in such timed relation by means of the lobe shaped cam 77 carried by the same shaft 78 which operates cam 71 of the cut-off mechanism 69. The level of the bottom of the track 74 is such'as to present the billet in the proper plane to be initially engaged by the dies of the rolls 2O and 21. But the cut-off dies and the bar feed 67 are above this plane whereby the end of linger may underlie the dies 7() and the bar 68 and the blank may be dropped into a position before the finger. In this manner dies 70 are continuous, yet finger 7 5 engages the end of the severed blank symmetricall and projects it with its center in the plane o symmetry of the machine and the dies.

Any other machine and anyother mecha.- nisms may be substituted for that which I have shown. The chief merit in that which I have shown is the simplicity, compactness and the greater freedom from interference with perfect performances of the one mechanism by another.

What I claim as new and useful and desire to protect by Letters Patent is:

1. The method of forming hinge butts v from bar stock which consists in forging the shank by forcing the metal of the stock peripherally while rolling it radially between cylindrical rolling surfaces, and forging the knuckle by radially rolling the metal of the blank between opposed concave and convex rolling surfaces.

2. The method of forging hinge butts from bar stock which consists in shaping the shank portion of a blank between cylindrical portions of a pair of rolls, and the knuckle portion between a projecting portion on one roll and a depression in the other roll.

3. The method of continuous forgingiof 'hinge butts from bar stock which consists in shaping a shank portion from a blank between cylindrical portions of a pair of rolls and then shaping a knuckle portion between ja projecting portion on one roll and a depression in the other roll.

4. 'The' method of continuous forging of hinge butts from bar stock which consists in shaping a shank portion from a blank between. cylindrical portions of a pair of rolls and then shaping the knuckle portion between a projecting portion on one roll and a depression .in the other roll by rolling pressure and angular extrusion of portions of the blank between the sides of said projection and depression to form thel ears of the knuckle portion.

. y 5. The method of rolling hinge butts' having hooded knuckles which consists in pocketing and vextruding theI blank by vintermeshing convex `and concave surfaces to form a depression on one side of the blank and an velevation on the other and thereupon rolling the depression and elevation to further size the same.

6. The method of rolling hooded hinge butts which consists in shapmg the blank by rolling of the hood portion between a pair of rolls having a geartooth-like projectlon on the one roll and a depression in the other roll, with the top of the hood portion approximately on the pitch line of the geartoothlike projection.

7. The method of rolling'hinge butts which consists in rolling the shankbetween cylindrical rolling surfaces under diierential rolling action and the knuckle under substantially equalized rolling action between opposed convex and concave surfaces.

8. The method of rolling hinge butts having bent Shanks which conslsts in shaping the outer end of the shank portion and a portion of the bend from a blank between cylindrical portions of a pair of rolls and shapin the remainder of the shank portion an the knuckle portion between a projection on the one roll and a depression in the other roll. 9. Thel method of continuous rolling of hinge butts' from bar stock which consists in severing the bar into lengths of suicient mass to embody the butt, and rolling the outer end of the blank to form the shank between substantially cylindrical rolling surfaces and then the inner end between opposed convex and concave surfaces to form the knuckle.

10. The method of rolling` hinge butts which consists in shaping the blank to form a shank portion of the butt between cylindrical portions of a pair of rolls and shaping thel knuckle portion between a rejection on one roll and a depression in t e other roll, and controllin the rolling of theknuckle by development o a holdinaction in the cylinj drical rolling of the sha In testimony whereof he hereunto airixes Y his signature.

, CAROLUS L. EKSERGIAN. 

